Washing, Sterilization, Filling and Closing of Bulk Vials

For aseptic processing, the glass containers are fed into the machine via a buffer to be washed and then sterilized.

In recent years, groninger has optimized the washing process through extensive tests and CFD studies and established it as a standard. Consequently, vials are efficiently cleaned on the inside and outside on our lines. After the up to 3-log reducing cleaning, the containers are dried and transported to the subsequent step, generally being sterilization.

Our sterile tunnel is designed to carry out gentle yet effective sterilization to a large extent; at the same time, the corresponding line areas are very easily accessible because they can be accessed from both sides, allowing it to be cleaned without any problems.

The new type of sterile tunnel developed by groninger works with gentle heating of the objects in the entry area to the sterilization area. The object itself is subject to only a small temperature difference, which means that overkill in the sterile process can be avoided. High-end sterile filters guarantee the highest quality.

Discover the unparalleled versatility of groninger automatic vial filling machines. From life-saving vaccines to delicate cosmetic medicines, our innovative technology ensures the safe and precise processing of a wide range of liquid formulations.

Our vial fillers are designed to accommodate diverse products, spanning from thin to viscous consistencies. Whether your formulation is water-like, WFI-based, or a quickly settling suspension, our machines deliver consistent results with uncompromising accuracy.

With expertise spanning various industries including pharmaceuticals, biopharmaceuticals, veterinary products, and cosmetics, we understand the unique requirements of each product category. From orphan drugs to biologics and beyond, our vial fillers provide unmatched versatility and reliability.

Experience peace of mind knowing that your valuable pharmaceuticals are in capable hands. Trust groninger automatic vial filling machines for efficient, safe, and precise liquid filling solutions tailored to your specific needs.

We also ensure highest quality when it comes to closing objects, particularly, making sure that no unnecessary particles get into the pharmaceutical product, as well as great flexibility and process reliability. groninger lines process a large number of different rubber stoppers, including the relatively young push-fit vial closure systems (e.g. RayDyLyo® or DAIKYO PLASCAP®).

To enable maximum flexibility, we limit the number of closure size-dependent sorting and feeding formats. Omitting vacuum-controlled lines makes cleaning, in particular, much easier. However, our stoppering systems are also easy to maintain and look after due to their sophisticated ergonomics and the good accessibility of all individual parts.

For the processing of sensitive products, the "headspace" can be gassed in a container to reduce the residual oxygen level to less than 1%. 

To further minimize product rejects, our vial filling machines can be designed with a re-stoppering function, allowing to the loss of a stopper to be compensated by repositioning it.

Freeze drying can extend the shelf life of many liquid medicines. The active ingredients remain intact and retain their effectiveness.

We have already integrated freeze drying in numerous lines. How exactly this process works, how it is mechanically and electrically integrated, is something we explain in detail for each project based on the specific requirements.

With a combined liquid and lyo line, a connection to the freeze dryer can be a great solution in a very space-saving manner. At the same time, it reduces the complexity of the isolator, which facilitates the changeover from the freeze-drying process to a liquid filling and closing process and reduces set-up times.

For liquid pharmaceuticals, vials can be sealed within one line or immediately afterwards on a separate, compact machine. Our capping process easily meets the requirements of EU GMP Annex 1 – this is a groninger standard.

groninger relies on the patented, very proven and low-particle single-disc sealing principle. That means, that our vial filling and capping machines closed the containers with an adjustable and non-slip closing disc. This is done in various performance classes from 10 to 600 objects per minute with extreme reliability. An optional extraction makes it possible to further reduce even the already low number of particles.

Compared to other solutions with several sealing discs, the line can be changed over much more quickly, and faults can be detected immediately; overall, it reduces the risk significantly. Vials with poorly-fitting stoppers can be rejected prior to the sealing process.

When processing toxic products, operator protection is a top priority in addition to pure product protection. That's why we attach great importance to the fact that vials filled with these drugs – in liquid form or as a powder after freeze-drying – are reliably cleaned on the outside.

With our extensive portfolio in the field of exterior cleaning, we are able to offer the right system for your product as well.

It must be able to track or sterilize individually produced products. For this reason, printing is important to code the individual object; it is the only way to track the product life cycle.

On the groninger lines, coding is not an independent process, but rather a solution integrated into the lines. Individual objects can usually be printed using an inkjet or engraved using a laser. Inkjet printing can also use UV ink, which only certain light sources make it visible.

The information required for coding is delivered securely and reliably to the printer and the inspection system.